Note: Descriptions are shown in the official language in which they were submitted.
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CA 02805785 2013-02-12
,
DUCT LINER
RELATED APPLICATION
[0001] The present application claims the benefit of US Provision Patent
Application
serial number 61/641,492, filed on May 2, 2012, which is incorporated herein
by
reference in its entirety.
FIELD OF THE INVENTION
[0002] The present application generally relates to ducts and, more
particularly, ducts
that are lined with liners that enhance the acoustical and/or thermal
performance of the
ducts.
BACKGROUND OF THE INVENTION
[0003] Ducts and conduits are used to convey air in building heating,
ventilation, and air
conditioning (HVAC) systems. Often these ducts are formed of sheet metal, and,
as a
result, do not possess good thermal or acoustical properties. In order to
enhance these
properties, the ducts are lined with a flexible or rigid thermal and sound
insulating
material. Duct insulation used in HVAC systems typically includes a facing
layer adhered
to an insulation layer. The insulation layer is often made from fiberglass.
The facing
material is commonly affixed to the insulation layer by an adhesive.
[0004] Some existing duct liners include coatings on the lateral edges of
the duct liners.
The coatings are typically sprayed onto the lateral edges. The edge coating
may be a
water based binder. The water based binder may be cured by applying heat
energy to the
duct liner.
[0005] The North American Insulation Manufacturers Association (NAIMA)
publishes
guidelines for the design, fabrication and installation of fibrous glass duct
liners. For
example, NAIMA published the third edition of the FIBROUS GLASS DUCT LINER
STANDARD - Design, Fabrication and Installation Guidelines in 2002. These
guidelines
1
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disclose a recommended guideline for the selection, fabrication and
installation of fibrous
glass duct liner insulations in sheet metal air handling ducts. Pages 19 and
22 of the 2002
guideline disclose installing a metal nosing on edges of duct liner facing the
air stream
when velocity exceeds 4000 FPM.
SUMMARY
[0006] The present application discloses exemplary embodiments of a duct
liner. In one
exemplary embodiment, the duct liner includes an insulation layer and a
facing. The
insulation layer having a first edge surface, a second edge surface that is
spaced apart
from the first edge surface, and a first and second face surfaces that extend
from the first
edge surface to the second edge surface. The facing is disposed on the first
face surface,
such that the first face surface is entirely covered by the facing. The facing
is disposed
on the first and second edge surfaces, such that the first and second edge
surfaces are
entirely covered by the facing. Two spaced apart strips of the facing are
disposed on and
cover a portion of the second face surface adjacent to the first and second
edge surfaces,
such that a portion of the second face surface between the strips is uncovered
by the
facing. The duct liner can be used in a wide variety of different ducts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Features and advantages of the present invention will become
apparent to those of
ordinary skill in the art to which the invention pertains from a reading of
the following
description together with the accompanying drawings, in which:
[0008] Fig. 1 is an end view of an exemplary embodiment of a duct liner;
[0009] Fig. IA is an end view of an exemplary embodiment of a duct liner;
[0010] Fig. 2 is a perspective view of the duct liner illustrated by Fig.
1;
[0011] Fig. 2A is a perspective view of material that may be cut to form
duct liners rolled
onto a roll;
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[0012] Fig. 3 is a perspective view of another exemplary embodiment of a
duct liner;
[0013] Figs. 4A-4C schematically illustrate an exemplary embodiment of a
method of
making a duct liner;
[0014] Figs. 5A-5C schematically illustrate an exemplary embodiment of a
method of
making a duct liner;
[0015] Figs. 6A-6C schematically illustrate an exemplary embodiment of a
method of
making a duct liner;
[0016] Figs. 7A-7D schematically illustrate an exemplary embodiment of a
method of
making a duct liner;
[0017] Figs. 8A-8D schematically illustrate an exemplary embodiment of a
method of
making a duct liner;
[0018] Fig. 9 is a sectional view of an exemplary embodiment of a duct
assembly;
[0019] Fig. 10 is a sectional view of another exemplary embodiment of a
duct assembly;
[0020] Fig. 10A is an illustration of an exemplary embodiment of a fastener
holding a
duct liner to a duct housing;
[0021] Fig. 10B is an illustration of an exemplary embodiment of a fastener
holding a
duct liner to a duct housing;
[0022] Fig. 10C is an illustration of an exemplary embodiment of a fastener
holding a
duct liner to a duct housing;
[0023] Fig. 10D is an illustration of an exemplary embodiment of a fastener
for holding a
duct liner to a duct housing;
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[0024] Fig. 10E is an illustration of an exemplary embodiment of a fastener
for holding a
duct liner to a duct housing;
[0025] Fig. 11 is a sectional view of another exemplary embodiment of a
duct assembly;
[0026] Fig. 12 is a perspective view of the duct assembly illustrated by
Fig. 11;
[0027] Figs. 13A and 13B illustrate an exemplary embodiment of a method of
assembling a duct assembly;
[0028] Fig. 14 is a sectional view of an exemplary embodiment of a duct
assembly;
[0029] Fig. 15 is a sectional view of another exemplary embodiment of a
duct assembly;
[0030] Fig. 16 is a perspective view of the duct assembly illustrated by
Fig. 15;
[0031] Fig. 17 is a sectional view of an exemplary embodiment of a duct
assembly;
[0032] Fig. 18 is a sectional view of another exemplary embodiment of a
duct assembly;
[0033] Fig. 19 is a perspective view of the duct assembly illustrated by
Fig. 18;
[0034] Figs. 20A and 20B illustrate an exemplary embodiment of a method of
assembling a duct assembly;
[0035] Fig. 21 is a sectional view of an exemplary embodiment of a duct
assembly;
[0036] Fig. 22 is a sectional view of an exemplary embodiment of a duct
assembly;
[0037] Fig. 23 is a sectional view of an exemplary embodiment of a duct
assembly;
[0038] Fig. 24A is a perspective view of components that form one-half of a
duct
assembly;
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[0039] Fig. 24B is a front end view of the duct assembly components
illustrated by Fig.
24A;
[0040] Fig. 24C is a top view of the duct assembly components illustrated
by Fig. 24A;
[0041] Fig. 24D is a side view of the duct assembly components illustrated
by Fig. 24A;
[0042] Fig. 25 is an end view of a duct assembly formed by assembling two
sets of the
duct assembly components illustrated by Figs. 24A-24D;
[0043] Fig. 26A is a perspective view of components that form one-half of a
duct
assembly;
[0044] Fig. 26B is a front end view of the duct assembly components
illustrated by Fig.
26A;
[0045] Fig. 26C is a top view of the duct assembly components illustrated
by Fig. 24A;
[0046] Fig. 26D is a side view of the duct assembly components illustrated
by Fig. 24A;
[0047] Fig. 27 is an end view of a duct assembly formed by assembling two
sets of the
duct assembly components illustrated by Figs. 26A-26D; and
[0048] Fig. 28 is a schematic illustration of a manufacturing line for
producing a wrapped
insulation product.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0049] Prior to discussing the various embodiments, a review of the
definitions of some
exemplary terms used throughout the disclosure is appropriate. Both singular
and plural
forms of all terms fall within each meaning:
[0050] As described herein, when one or more components are described as
being
connected, joined, affixed, coupled, attached, or otherwise interconnected,
such
CA 02805785 2013-02-12
interconnection may be direct as between the components or may be indirect
such as
through the use of one or more intermediary components. Also as described
herein,
reference to a "member," "component," or "portion" shall not be limited to a
single
structural member, component, or element but can include an assembly of
components,
members or elements. "Physical communication" as used herein, includes but is
not
limited to connecting, affixing, joining, attaching, fixing, fastening,
placing in contact
two or more components, elements, assemblies, portions or parts. Physical
communication between two or more components, etc., can be direct or indirect
such as
through the use of one or more intermediary components and may be intermittent
or
continuous.
[0051] In the embodiments discussed herein, the insulation arrangements of
the present
application are described for use with a ducts. However, the insulation
arrangements of
the present application may be used in a variety of different applications.
The present
patent application specification and drawings provide multiple embodiments of
insulation
arrangements and duct assemblies. Any feature or combination of features from
each of
the embodiments may be used with features or combinations of features of other
embodiments.
[0052] Figs. 1 and 2 illustrate an exemplary embodiment of a duct liner 10.
The
illustrated duct liner 10 includes an insulation layer 12 and a facing 14. The
insulation
layer 12 may take a wide variety of different forms. In the illustrated
embodiment, the
insulation layer 12 is rectangular with a leading edge 15 and a trailing edge
17 (See Fig.
2). However, the insulation layer 12 may have any shape to accommodate the
desired
application the duct liner 10.
[0053] The illustrated insulation layer 12 includes a first lateral edge
surface 16, and a
second lateral edge surface 18 that is spaced apart from the first lateral
edge surface. A
first face surface 20 extends from the first lateral edge surface 16 to the
second lateral
edge surface 18. A second face surface 22 is opposed to and spaced apart from
the first
face surface 20 and also extends from the first lateral edge surface 16 to the
second lateral
edge surface 18.
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[0054] The facing 14 is wrapped around the insulation layer 12. The facing
14 can be
wrapped around the insulation layer 12 in a wide variety of different ways.
The facing 14
can be wrapped around one ore both of the lateral edge surfaces 16, 18. The
facing 14
can optionally be wrapped around the leading edge 15 and/or the trailing edge
17 (see
Fig. 3). The facing 14 is a single piece of material in one exemplary
embodiment (see
Fig. 1). In another exemplary embodiment, the facing is made from multiple
different
pieces or sheets of material. For example, a first piece or sheet of material
may cover the
first face surface 20 and two strips 24 of facing material may be wrapped
around the
lateral edge surfaces 16, 18 of the insulation layer 12 (see Fig. 1A).
[0055] In the exemplary embodiment illustrated by Figs. 1 and 2, the facing
14 is
disposed on the first face surface 20, such that the first face surface is
entirely covered by
the facing 14. The facing 14 is also disposed on the first and second lateral
edge surfaces
16, 18, such that the first and second edge surfaces are entirely covered by
the facing.
Two spaced apart strips 26 extend from the facing portions 28 that cover the
first and
second lateral edge surfaces 16, 18. The spaced apart strips 26 are disposed
on and cover
a portion of the second face surface 22 adjacent to the first and second
lateral edge
surfaces 16, 18. A portion 30 of the second face surface 22 between the strips
26 is not
covered by the facing in the illustrated embodiment. In another exemplary
embodiment,
the second face surface 22 is completely covered by the facing 14. For
example, the
strips 26 may be sized so that one strip meets or overlaps the other strip to
thereby
completely cover the second face surface 22 and substantially encapsulate the
insulation
layer 12.
[0056] Fig. 2 illustrates the duct liner 10 in a rectangular configuration.
This duct liner
may be flexible for installation in a metal duct assembly or may be rigid and
may be used
as a duct board with or without a metal duct. In the example illustrated by
Fig. 2A, the
duct liner 10 is flexible, which allows the duct liner to be rolled onto a
roll 200. The
illustrated roll has a width W. The width W can be selected to accommodate a
wide
variety of different applications. Referring to Figures 2A and 24A for
example, the width
W of the duct liner roll 200 may correspond to the length L of a duct section
2400 (two of
the assemblies illustrated by Fig. 24A are assembled to form a duct section
2400). By
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having the width W of the roll 200 correspond to the length L of the duct
sections, duct
sections 2400 with leading and/or trailing ends 2402, 2404 having edge
surfaces 16, 18
that are entirely covered by the facing 14 can be easily manufactured. This
wrapping of
the edge surfaces 16, 18 at the leading and trailing edges 2402, 2404
eliminates the need
to install a metal nosing on the leading edge surface 16 facing the air stream
when
velocity exceeds 4000 FPM. Referring to Figs. 2A and 9 for example, the width
W of the
duct liner roll 200 may correspond to the interior perimeter of a duct. In
this example,
any requirement of forming a seal along the seam S where the ends of the duct
liner ends
meet is eliminated, since the edge surfaces 16, 18 are covered by the facing
14. Referring
to Figs. 2A and 13A for example, the width W of the duct liner roll 200 may
correspond
to the interior perimeter of a duct half. In this example, any requirement of
forming seals
along the seams S where the ends of the duct liner ends meet is eliminated,
since the edge
surfaces 16, 18 are covered by the facing 14. Referring to Figs. 2A and 14 for
example,
the width W of the duct liner roll(s) 200 may correspond to duct liner panels
or sides for a
given duct liner size. In this example, any requirement of forming seals along
the seams
S where the ends of the duct liner ends meet is eliminated, since the edge
surfaces 16, 18
are covered by the facing 14.
[0057] The insulation layer can be made from a wide variety of different
materials and
can take a wide variety of different forms. In one exemplary embodiment, the
insulation
layer 12 is flexible to allow the duct liner 10 to be folded, rolled, or
otherwise
manipulated. In another embodiment, the insulation layer 12 is rigid or board-
like. In
one exemplary embodiment, the insulation layer is made from a fibrous
material. For
example, the insulation layer may comprise fiberglass insulation, such as a
bonded
blanket of short glass fibers, such as the blanket used in QuietR rotary duct
liner
available from Owens Corning, a bonded blanket of long glass fibers, such as
the blanket
used in the QuietRO textile duct liner available from Owens Corning, or
organic and/or
inorganic fibers in a thermosetting resin formed into flexible, semi-rigid, or
rigid boards.
The insulation layer 12 may be constructed from glass fibers such that the
duct liner
meets the physical property requirements of ASTM C 1071, Standard
Specification for
Thermal and Accoustical Insulation (Glass Fiber Duct Lining Material).
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[0058] As noted above, the insulation layer 12 may be made from a wide
variety of
different materials. The materials may include glass fibers as mentioned above
and can
also include a wide variety of different materials . Examples of materials
that the
insulation layer 12 can be made from include, but are not limited to, nonwoven
fiberglass
and polymeric media, woven fiberglass and polymeric media, foam, including
plastic
foam and rubber foam, honeycomb composites, mineral wool, rock wool, ceramic
fibers,
glass fibers, aerogels, vermiculite, calcium silicate, fiberglass matrix,
polymeric fibers,
synthetic fibers, natural fibers, composite pre-forms, cellulose, wood, cloth,
fabric and
plastic. The insulation layer may be fire resistant, may include an
antimicrobial material,
and/or may be made from over 55% recycled material. As used in this
application, the
term "natural fiber" is meant to indicate plant fibers extracted from any part
of a plant,
including, but not limited to, the stein, seeds, leaves, roots, or bast. The
insulation layer
may be formed of organic fibers such as rayon, polyethylene, polypropylene,
nylon,
polyester, and mixtures thereof. Continuous fibers and/or multi-component
fibers such as
bicomponent or tricomponent polymer fibers may also be utilized in forming the
insulation layer 12. The bicomponent fibers may be formed in a sheath-core
arrangement
in which the sheath is formed of first polymer fibers that substantially
surround a core
formed of second polymer fibers. The insulation layer 12 may be a non-woven
web
formed by conventional dry-laid processes or the insulation layer may be point
bonded,
woven, and other non-woven materials such as needled, spunbonded, or meltblown
webs
may be used. A binder, flame-retardants, pigments, and/or other conventional
additives
may also be included in the insulation layer 12. Optionally, the insulation
layer 12 may
be treated with a fungicide and/or bactericide either during or after
manufacturing.
Similarly, the waterless, thin-film adhesive may be heat bonded to a
insulation layer 12
and subsequently applied to a fibrous insulation product. The insulation layer
can be
made from any material that provides the thermal and/or acoustical insulation
properties
required by the application.
[0059] When the insulation layer 12 is made from glass fibers, the
insulation layer may
be formed of matted glass fibers that are bonded together by a cured thermoset
polymeric
material. The manufacture of glass fiber insulation products may be carried
out in a
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continuous process by fiberizing molten glass and immediately forming a
fibrous glass
batt on a moving conveyor. The glass may be melted in a tank (not shown) and
supplied
to a fiber forming device such as a fiberizing spinner. Non-limiting examples
of glass
fibers that may be utilized in the present invention are described in U.S.
Pat. No.
6,527,014 to Aubourg; U.S. Pat. No. 5,932,499 to Xu et al.; U.S. Pat. No.
5,523,264 to
Mattison; and U.S. Pat. No. 5,055,428 to Porter, the contents of which are
expressly
incorporated by reference in their entirety. The glass fibers, are sprayed
with an aqueous
binder composition. Although any conventional binder such as phenol-
formaldehyde and
urea-formaldehyde may be used, the binder is desirably a low formaldehyde
binder
composition, such as a polycarboxylic based binder, a polyaciylic acid
glycerol (PAG)
binder, or a polyaciylic acid triethanolamine (PAT binder). Suitable
polycarboxy binder
compositions for use in the instant invention include a polycarboxy polymer, a
crosslinking agent, and, optionally, a catalyst. Such binders arc known for
use in
connection with rotary fiberglass insulation. Examples of such binder
technology are
found in U.S. Pat. Nos. 5,318,990 to Straus; 5,340,868 to Straus etal.;
5,661,213 to
Arkens et al.; 6,274,661 to Chen et al.; 6,699,945 to Chen et al; and
6,884,849 to Chen et
al., each of which is expressly incorporated entirely by reference. The binder
may be
present in an amount from about 2% to about 25% by weight of the total
product, and
preferably from about 5% to about 20% by weight of the total product, and most
preferably from about 10% to about 18% by weight of the total product.
[0060] The
facing 14 may take a wide variety of different forms. The facing 14 may be a
single sheet of material or several layers of material. The facing my include
multiple
overlaying sections of material as illustrated by Fig. 1A. Further, portions
of the
illustrated facings 14 may be removed. For example, one of the lateral edges
16, 18 may
be covered with the facing 14, while the other lateral edge is not covered by
the facing.
Referring to Figures 4A-4C, the facing 14 may be pre-folded such that the
facing
includes a predefined central portion 36 that covers the first face surface
20, a pair of
predefined edge covering portions 28 on opposite sides of the predefined
central portion
36, and the pair of strips 26 are predefined and extend from the pair of
predefined edge
covering portions 28.
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[0061] The facing 14 may be made from a wide variety of different
materials. For
example, the facing 14 may comprise nonwoven fiberglass and polymeric media,
woven
fiberglass and polymeric media, sheathing materials, such as sheathing films
made from
polymeric materials, scrim, cloth, fabric, tapes kraft paper or material, and
fiberglass
reinforced kraft paper (FRK). The facing may be an FRK vapor retarder facing
that is
used on QuietRO duct board available from Owens Coming. The facing 14 may be
black, high density, durable glass mat facing that is used on the QuietRt
Rotary Duct
Liner or QuietRe Textile Duct Liner available from Owens Coming. The facing
may be
fire resistant, may provide a cleanable surface, may include an antimicrobial
material,
and/or may be made from over 55% recycled material. The facing may be porous.
Any
material that reduces airflow resistance (as compared to the airflow
resistance of the
uncovered insulation layer 12), that isolates that insulation layer 12 from
airflow, and/or
that makes the duct liner 10 easier to clean can be used.
[0062] In one exemplary embodiment, the facing 14 is suitable for a fibrous
insulation
product. Facing materials that are suitable for fibrous insulation products
include, but are
not limited to, a nonwoven mat, web, or a veil. The facing may include a
waterless, thin-
film adhesive adhered thereto. The facing 14 may include a fibrous web and a
waterless,
thin-film adhesive adhered to a major surface of the fibrous web. The fibrous
web may be
formed from fibers such as, but not limited to, glass fibers, mineral wool,
rock wool,
polymer fibers, synthetic fibers, and/or natural fibers. As used in this
application, the
term "natural fiber" is meant to indicate plant fibers extracted from any part
of a plant,
including, but not limited to, the stein, seeds, leaves, roots, or bast.
Desirably, the fibrous
web is formed of organic fibers such as rayon, polyethylene, polypropylene,
nylon,
polyester, and mixtures thereof Continuous fibers and/or multi-component
fibers such as
bicomponent or tricomponent polymer fibers may also be utilized in forming the
facing
14. The bicomponent fibers may be formed in a sheath-core arrangement in which
the
sheath is formed of first polymer fibers that substantially surround a core
formed of
second polymer fibers. Although the facing is preferably a non-woven web
formed by
conventional dry-laid processes, other materials such as point bonded, woven,
and other
non-woven materials such as needled, spunbonded, or meltblown webs may be
used. A
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binder, flame-retardants, pigments, and/or other conventional additives may
also be
included in the facing 14. Optionally, the facing 14 may be treated with a
fungicide
and/or bactericide either during or after manufacturing. Similarly, the
waterless, thin-film
adhesive may be heat bonded to a facing 14 and subsequently applied to a
fibrous
insulation product.
[0063] The facing 14 may be disposed on the insulation layer 12 in a wide
variety of
different ways. In one exemplary embodiment, the facing 14 is adhered to the
insulation
layer 12. Any portion of the facing 14 can be adhered to any portion of the
insulation
layer. For example, the strips 26 are adhered to the second face surface 22,
the facing
portions 28 are adhered to the first and second lateral edge surfaces 16, 18
of the
insulation layer 12, and/or the facing 14 is adhered to the first face surface
20. In one
exemplary embodiment, the strips 26 are adhered to the second face surface 22,
the
facing portions 28 are not adhered to the first and second lateral edge
surfaces 16, 18 of
the insulation layer 12, and the facing 14 is adhered to the first face
surface 20. Any
portion or portions of the facing 14 can be adhered to any portion or portions
of the
insulation layer.
[0064] The facing 14 can be adhered to the insulation layer 12 in a wide
variety of
different ways. For example, the facing can be adhered to the insulation layer
with an
adhesive, by ultrasonic welding, or the facing can be fastened to the
insulation layer by
mechanical fasteners. A wide variety of different adhesives can be used to
adhere the
facing 14 to the insulation layer 12. For example, the adhesive can be a water
base
adhesive, a one part adhesive, a two part adhesive, a powder adhesive, a hot
melt
adhesive, thin film adhesives, a binder, such as a formaldehyde free binder
and a
spunbond hot melt adhesive web. Spunbond hot melt adhesive webs are available
from
Spunfab of Cuyahoga Falls, OH. The adhesive 32 may be applied in a wide
variety of
different ways. The adhesive may be applied to the insulation layer 12 and/or
the facing
14, for example by spraying, rolling, brushing, etc. When a binder is used,
the binder may
be a binder that is part of the insulation layer 12 and/or the facing 14 and
curing of the
binder adheres the insulation layer 12 to the facing 14. In one exemplary
embodiment,
the adhesive is applied to the strips 26 to adhere the strips to the second
face surface 22,
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adhesive is not applied to the facing portions 28 such that the facing
portions 28 are not
adhered to the first and second lateral edge surfaces 16, 18 of the insulation
layer 12, and
adhesive is applied to the central portion 36 of the facing 14 such that the
central portion
36 is adhered to the first face surface 20. In one exemplary embodiment, the
adhesive is
applied to the second face surface 22 of the insulation layer 12 to adhere the
strips 26
thereto, adhesive is not applied to the first and second lateral edge surfaces
16, 18 such
that the facing portions 28 are not adhered to the first and second lateral
edge surfaces 16,
18 of the insulation layer 12, and adhesive is applied to the first face
surface 20 such that
that the central portion 36 is adhered to the first face surface 20. The duct
liner 10 may
be easier to roll and/or may be easier to form into the shape of a duct if the
lateral edge
surfaces 16, 18 are not adhered to the facing portions 28.
[0065] In one exemplary embodiment, the adhesive is a waterless, thin-film
adhesive,
such as a thermoplastic that is heat activated. In exemplary embodiments, the
waterless,
thin-film adhesive has a thickness less than or equal to about 60 microns,
from about 6.0
to about 30.0 microns, or from about 10 microns to about 15 microns. The
waterless,
thin-film adhesive is applied to the facing material via the application of
heat. For
instance, the waterless, thin-film adhesive may be positioned on the facing
and then
adhered to the facing by heating the facing material with a hot plate or other
suitable
heating device (e.g., an oven). The facing material may similarly be adhered
to the
insulation layer 12 by heating the facing and the insulation layer to a
temperature at or
above the melting point of the waterless, thin-film adhesive for a time
sufficient to adhere
the facing to the insulation layer. Non-limiting examples of suitable
adhesives include an
ethylene copolymer, polyurethane, ethylene vinyl acetate (EVA), amorphous
polyolefin,
polyethylene, low density polyethylene (LDPE), cellophane, polyethylene
terephthalate
(PETP), polyvinyl chloride (PVC) nylons, polypropylene, polystyrene,
polyamides, and
cellulose acetate.
[0066] A wide variety of mechanical fastening arrangements may be used to
fasten the
facing 14 to the insulation layer 14. The mechanical fastening arrangements
may be used
in combination with or in lieu of adhesives, ultrasonic welding, and/or other
types of
bonding. Examples of mechanical fastening arrangements that can be used to
connect the
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facing 14 to the insulation layer 14 include, but are not limited to, pinning,
needling,
sewing, and gripping or friction type fasteners. Any type of fastener that
allows the
facing 14 to be attached to the insulation layer 12 can be used.
[0067] Figs. 4A-4C, 5A-5C, 6A-6C, 7A-7D, and 8A-8D illustrate exemplary
embodiments of methods of making a duct liners. In each of these methods, an
insulation
layer 12 and a facing 14 are provided. The facing 14 is wrapped around the
insulation
layer 12, such that the facing is disposed on the first face layer 20, on the
first and second
edge surfaces 16,18, and two spaced apart strips 26 of the facing are disposed
on and
cover a portion of the second face surface 22 adjacent to the first and second
edge
surfaces 16, 18. In the illustrated embodiment, the portion 30 of the second
face surface
22 between the strips 26 is uncovered by the facing 14.
[0068] In the exemplary embodiment illustrated by Figs. 4A-4C, a preformed
insulation
layer 12 is placed on top of the facing 14 (see Fig. 4A). The facing may
optionally be
pre-folded, pre-formed, or pleated. For example, the facing may have crease
lines 38 that
are positioned on the facing to correspond to the width W of the insulation
layer 12 and
may have crease lines 40 that correspond to the thickness T of the insulation
layer. The
facing 14 may be wound on a roll after the pre-folding or pleating. Then, the
facing may
be unwound from the roll when the duct liner 10 is being fabricated. An
adhesive is
provided on the insulation layer 12 and/or the facing (see Fig. 4A). The
adhesive may be
sprayed on the adhesive may be pre-applied and/or be part of the insulation
layer 12
and/or the facing. Referring to Fig. 4B, the facing 14 is folded to cover the
lateral side
edges. Referring to Fig. 4C, the facing 14 is folded onto the second face
surface 22 to
form the spaced apart strips 26. The adhesive 32 is cured to form the finished
duct liner
10.
[0069] In the exemplary embodiment illustrated by Figs. 5A-5C, a facing 14
is placed on
top of a preformed insulation layer 12 (see Fig. 5A). The facing may
optionally be pre-
folded, pre-formed, or pleated. For example, the facing may have crease lines
38 that are
positioned on the facing to correspond to the width W of the insulation layer
12 and may
have crease lines 40 that correspond to the thickness T of the insulation
layer. This
14
CA 02805785 2013-02-12
prefolding of the facing defines a central portion 36 that covers the first
face surface 20,
the pair of edge covering portions 28 on opposite sides of the central
portion, and the pair
of strips 26 extend from the pair of edge covering portions. The facing 14 may
be wound
on a roll after the pre-folding or pleating. Then, the facing may be unwound
from the roll
when the duct liner 10 is being fabricated. An adhesive is provided on the
insulation
layer 12 and/or the facing 14. The adhesive 32 may be sprayed on or the
adhesive may
be pre-applied and/or be part of the insulation layer 12 and/or the facing 14.
Referring to
Fig. 5B, the facing 14 is folded to cover the lateral side edges 16, 18.
Referring to Fig.
5C, the facing 14 is folded onto the second face surface 22 to form the spaced
apart strips
26. The adhesive is cured to form the finished duct liner 10.
[0070] In the exemplary embodiments illustrated by Figs. 6A-6C, the
insulation layer 12
is formed directly on top of the facing 14. This direct forming may be done in
a variety
of different ways. For example, US Published Patent Application No.
2010/0000170 to
Parks, which is incorporated herein by reference, discloses methods of
applying a pack of
glass fibers to a facing and vice versa. However, any type of insulation layer
12 can be
formed directly on top of the facing 14. In another embodiment, the facing 14
is
provided on top of an uncured pack of glass fibers (see for example Fig. 4 of
US
2010/0000170 and Figs. 5A-5C of the present application).
[0071] Referring to Fig. 6A and Fig. 28, which corresponds to Fig. 2 of US
Published
Patent Application No. 2010/0000170, fiberizing spinners 115 (Fig. 28) form
glass fibers
130 that are blown generally downwardly to position the glass fibers 130 on
the facing
within a forming chamber 125. In an exemplary embodiment, the glass fibers,
while still
hot, are sprayed with an aqueous binder composition. Guides 44 (Fig. 6A) may
be
included to define the sides of the pack 140. The guides 44 may be included at
any point
along the line illustrated by Fig. 28 or a station may be added where the
width of the
insulating layer 12 is defined. The glass fibers 130 having the uncured
resinous binder
adhered thereto may be gathered and formed into an uncured pack 140 by the
guides 44
on the facer 12 on an endless forming conveyor 145. The facing 14 may have a
pre-
applied waterless, adhesive disposed on the side that the glass fibers 130 are
being
applied to. This adhesive may be applied to the entire surface of the facing,
or only the
CA 02805785 2013-02-12
portion that the glass fibers are dropped onto. The facing may be supplied to
the
conveyor 145 by a roll 190.
[0072] The insulation pack may be compressed to allow the facing 14 to be
wrapped
around the lateral edges 16, 18 of the compressed uncured pack 140. For
example, the
uncured pack 140 may be compressed by upper and lower conveyors 165, 170 to
form
the faced fibrous insulation product 10 having a predetermined thickness (see
Fig. 28).
As with all of the embodiments disclosed herein, the facing 14 illustrated by
Figs. 6A-6C
may optionally be pre-folded, pre-formed, or pleated. An adhesive is provided
on the
insulation layer 12 and/or the facing 14 and/or the binder of the insulation
layer may be
used to adhere the insulation layer 12 to the facing 14.. The pack 140 and the
facing 14
are heated, such as by conveying the pack 40 through a curing oven 160 where
heated air
is blown through the insulation pack 140 and facing to evaporate any remaining
water in
the binder, cure the binder and the adhesive, rigidly bond the fibers together
in the
insulation pack 140, and adhere the facing 14 to the insulation pack 140.
Referring to
Fig. 6C, the facing 14 is folded to cover the lateral side edges and is folded
onto the
second face surface 22 to form the spaced apart strips 26. For example, the
facing 14
may be folded onto the insulation pack 140 as shown in Fig. 6C near an exit
161 of the
curing oven 160 of Fig. 28. However, the line may be configured in a wide
variety of
different ways to fold the facing 14 onto the insulation pack 140.
[0073] The duct liner 10 exits the curing oven 160 and may be rolled by
roll-up device
182 for storage and/or shipment. The wrapped fibrous insulation product 10 may
subsequently be unrolled and cut or die pressed to form fibrous insulation
parts (e.g., duct
liners and duct boards). Alternatively, the faced fibrous insulation product
10 may be cut
to a predetermined length by a cutting device such as a blade or knife to form
panels 184
of the faced fibrous insulation. If desired, channels or grooves, such as v-
shaped grooves,
may be formed in the inner surface of the duct liner 10 for folding or bending
the duct
liner to fit in a duct.
[0074] Figs. 7A-7D illustrate an exemplary embodiment where an insulation
layer 12,
such as an uncured pack 140 of glass fibers 130, is provided on top of the
facing 14. For
16
1
CA 02805785 2013-02-12
example, the uncured pack 140 may be formed directly on the facing as in the
embodiment of Figs. 6A-6C or the uncured pack 140 may be formed at a first
location
and then placed or conveyed onto the facing 14. Referring to Fig. 7B, once the
material
that forms the insulation layer is in contact with the facing 14, the
insulation layer 12 is
cut to define the first and second edge surfaces 16, 18. This cutting may be
done in a
wide variety of different ways. In the example illustrated by Fig. 7B, a
cutting tool 50 is
provided close to, but a predetermined distance away from, the facing 14 to
cut the
insulation layer 12 and define the first and second edge surfaces 16, 18
without cutting
the facing 14.
[0075] As with all of the embodiments disclosed herein, the facing 14
illustrated by Figs.
7A-7D may optionally be pre-folded, pre-formed, or pleated. An adhesive is
provided on
the insulation layer 12 and/or the facing 14 and/or the binder of the
insulation layer may
be used to adhere the insulation layer 12 to the facing 14.. Referring to Fig.
7D, the
facing 14 is folded to cover the lateral side edges and is folded onto the
second face
surface 22 to form the spaced apart strips 26. The adhesive and/or the binder
of the
insulation layer 12 is cured to form the finished duct liner 10.
[0076] Figs. 8A-8D illustrate another exemplary embodiment where an
insulation layer
12, such as an uncured pack 140 of glass fibers 130, is provided on top of the
facing 14.
For example, the uncured pack 140 may be formed directly on the facing as in
the
embodiment of Figs. 6A-6C or the uncured pack 140 may be formed at a first
location
and then placed or conveyed onto the facing 14. Referring to Fig. 8B, once the
material
that forms the insulation layer is in contact with the facing 14, the
insulation layer 12 is
compressed to define said first and second edge surfaces 16, 18 and set the
height of the
insulation layer 12. This compressing may be done in a wide variety of
different ways.
In the example illustrated by Fig. 8B, the uncured pack 140 is pressed
laterally inward as
indicated by arrows 52 and down as indicated by arrows 54.
[0077] As with all of the embodiments disclosed herein, the facing 14
illustrated by Figs.
8A-8D may optionally be pre-folded, pre-formed, or pleated. An adhesive is
provided on
the insulation layer 12 and/or the facing 14 and/or the binder of the
insulation layer may
be used to adhere the insulation layer 12 to the facing 14.. Referring to Fig.
8D, the
facing 14 is folded to cover the lateral side edges and is folded onto the
second face
17
i
CA 02805785 2013-02-12
surface 22 to form the spaced apart strips 26. The adhesive and/or the binder
of the
insulation layer 12 is cured to form the finished duct liner 10.
[0078] Referring to Figs. 9-27, the duct liner 10 may be secured to an
interior surface of a
duct housing 900 to form an insulated duct assembly 902. The illustrated duct
housing
900 duct housing having an interior surface 904 and an exterior surface 906.
In the
illustrated exemplary embodiments, the duct liner 10 is oriented such that the
strips 26 of
the facing 14 face the interior surface 904 of the housing. In an exemplary
embodiment,
the strips 26 of the facing 14 are secured to the duct housing 900.
[0079] In the exemplary embodiments illustrated by Figures 9-23, the duct
liners 10 are
oriented such that the strips 26 are parallel to the longitudinal direction of
the duct
assembly. As such, seals between abutting duct liner ends are not needed,
since the ends
are completely covered by the facing 14. In the exemplary embodiments
illustrated by
Figs 24-27, the duct liners 10 are oriented such that the strips 26 are
perpendicular to the
longitudinal direction of the duct assembly 902. As such, leading and trailing
edge
surfaces 16, 18 are covered by the facing 14 and are protected from airflow
through the
duct.
[0080] The strips 26 of the facing may be secured to the duct housing in a
wide variety of
different ways. For example, the strips 26 of the facing 14 may be secured to
the duct
housing 900 with a fastener 908 (See Fig. 10) and/or with an adhesive. Any
manner of
securing the strips 26 of the facing 14 to the housing 900 can be used. In one
exemplary
embodiment, the uncovered portion 30 of the second face surface 22 of the duct
liner 10
is optionally secured to the duct housing 900. The uncovered portion 30 may be
secured
to the duct housing in a wide variety of different ways. For example, the
uncovered
portion 30 may be secured to the duct housing 900 with fasteners 1100 (See
Fig. 11)
and/or with an adhesive. The fasteners 908 may be substantially the same as
the fasteners
1100 or the fasteners 908 may be different than the fasteners 1100. Any manner
of
securing the uncovered portion 30 to the housing 900 can be used.
18
CA 02805785 2013-02-12
[0081] The duct assembly 902 may have a wide variety of different
configurations. Figs.
9-27 illustrate a few of the possible configurations. In the examples
illustrated by Figs.
9-27, the housing 900 has a rectangular shape in cross-section. However, the
housing
may have any shape. In the example illustrated by Fig. 9, a single piece of
duct liner 10
is used to insulate the entire interior surface 904 of the duct housing 900.
The example
illustrated by Fig. 9 and the other examples disclosed herein where the strips
24 are
parallel to the longitudinal direction of the duct assembly 902, the
orientation of the duct
liner may be changed such that the strips 24 are perpendicular to the
longitudinal
direction of the duct assembly. The duct liner 10 is folded at the corners
910, 912, 914.
At the corner 916, the ends of the duct liner 10 are lapped and compressed.
The portion
28 of the facing 14 on the lateral edge 18 engages a portion of the facing 14
on the face
surface 20. As such, no portion of the insulation layer 12 is exposed to the
airflow
through the duct assembly. The strips 26 and/or the uncovered portion 30 may
be
secured to the duct housing 900 in an exemplary embodiment.
[0082] Fig. 10 illustrates and exemplary embodiment that is similar to the
exemplary
embodiment illustrated by Fig. 9, except the duct liner 10 is secured to the
duct housing
900 by fasteners 908. The fasteners 908 and other fasteners mentioned in this
application
may take a wide variety of different forms. For example, referring to Figs.
10A, 10B, 10
C, 10D, and 10E, the fasteners 908 may comprise pins 1000 that are attached to
the duct
housing with heads 1002 connected to the end of the pins. The heads 1002 hold
the duct
liner 10 securely against the duct housing 900. In the example illustrated by
Fig. 10A,
the head 1002 is attached to the pin 1000. The pin 1000 is impact driven into
the duct
housing to form a positive mechanical attachment to the duct housing. In the
example
illustrated by Fig. 10B, the head 1002 is attached to the pin 1000. The pin
1000 is impact
welded to the duct housing, such as by resistance or capacitance welding. In
the example
illustrated by Fig. 10C, the head 1002 is attached to a large base 1010. The
large base
1010 allows the pin 1000 to be connected to the housing by an adhesive or by
welding.
In the example illustrated by Fig. 10C, the head 1002 is pressed onto the pin
1000 to
secure the duct liner 10 to the duct housing 900. The head may take a wide
variety of
different forms. In one exemplary embodiment, the head 1002 is configured to
prevent
19
CA 02805785 2013-02-12
the head from damaging the facing 14. For example, in the example illustrated
by Fig.
10D, the head is cupped and in the example illustrated by Fig. 10E, the head
is beveled.
It should be readily apparent that a wide variety of other types of fasteners
could also be
used to secure the duct liner to the duct housing 900.
[0083] The fasteners may be configured to connect the duct liner 10 to the
duct housing
900 in a wide variety of different ways. In the example illustrated by Fig.
10, the fastener
908 is secured to the duct housing 900. The fasteners 908 each extend through
one of the
strips 26 of the facing 14, through the insulation layer 12, and through the
central portion
36 of the facing 14 that is disposed on the first face 20 of the insulation
layer. This
arrangement securely attaches the two ends of the duct liner 10 to the duct
housing 900.
The strips 26 provide an extra layer of reinforcement to the two ends of the
duct liner 10.
The strips 26 may also be adhered to the interior surface 904 of the duct
housing 900 by
an adhesive.
[0084] Figs. 11 and 12 illustrate an exemplary embodiment that is similar
to the
exemplary embodiment illustrated by Fig. 10, except the duct liner 10 is
secured to the
duct housing 900 by fasteners 908 that extend through the strips 26 of the
facing and by
fasteners 1100 that do not extend through the strips 26. In the example
illustrated by
Figs. 11 and 12, the fasteners 908, 1100 are secured to the duct housing 900.
The
fasteners 908 each extend through one of the strips 26 of the facing 14,
through the
insulation layer 12, and through the central portion 36 of the facing 14 that
is disposed on
the first face 20 of the insulation layer. The fasteners 1100 each extend
through the
insulation layer 12, and through the central portion 36 of the facing 14 that
is disposed on
the first face 20 of the insulation layer, but do not extend through one of
the strips 26 of
the facing 14. This arrangement securely attaches both the two ends 918, 920
of the duct
liner 10 and the uncovered portion 30 of the duct liner 10 to the duct housing
900. The
strips 26 provide an extra layer of reinforcement to the two ends 918, 920.
The strips 26
and/or the uncovered portion 30 may also be adhered to the interior surface
904 of the
duct housing 900 by an adhesive.
1
CA 02805785 2013-02-12
,
. .
[0085] Referring to Fig. 12, the spacing between the fasteners 908, 1100
may be selected
based on the velocity of the air that will flow through the duct. In one
exemplary
embodiment, the spacing between the fasteners 908, 1100 is as follows:
Reference Description Dimension for 0- Dimension for
2500 feet per 2501-6000 feet per
minute minute
A From corners of duct to 1-4" 1-4"
fasteners 1100
A' From corners of duct to 1-2" 1-2"
fasteners 908
B From transverse end of duct 1-3" 1-3"
liner
C Across width of duct, on 10-14" 4-6"
centers (min. 1 per side)
D Along length of duct, on 17-18" 14-16"
centers (min. 1 per side)
[0086] The duct housing 900 may be formed in a wide variety of different
ways. The
duct housing 900 may be made from sheetmetal, plastic, or other materials. In
one
exemplary embodiment, the duct housing is made from bent sheetmetal. Referring
to
Figs. 13A and 13B, pieces 1300 of duct liner 10 are secured to L-shaped
sheetmetal
panels 1302. The example illustrated by Figs. 13A and 13B and the other
examples
disclosed herein where the strips 24 are parallel to the longitudinal
direction of the duct
assembly 902, the orientation of the duct liner pieces may be changed such
that the strips
24 are perpendicular to the longitudinal direction of the duct assembly. The
pieces 1300
21
,
CA 02805785 2013-02-12
may be applied to the sheetmetal panels 1302, before or after the panels are
bent into the
L-shape. Referring to Fig. 13B, two L-shaped sheetmetal panels with attached
duct liner
are assembled together to form a duct assembly 902. In other embodiments, the
duct
housing 900 is formed from more or less sheetmetal panels. For example, the
duct
housing 900 may be formed from a single piece of sheetmetal.
[0087] Fig. 14 illustrates another duct assembly configuration. In the
example illustrated
by Fig. 14, four pieces of duct liner 10 are used to insulate the interior
surface 904 of the
duct housing 900. The duct liner 10 is lapped an compressed at the corners
1410, 1412,
1414, 1416. Portions 28 of the facing 14 on the lateral edges 16 engage the
facing 14 on
the first face surface. As such, no portion of the insulation layer 12 is
exposed to the
airflow through the duct assembly. The strips 26 and/or the uncovered portion
30 may be
secured to the duct housing 900 in an exemplary embodiment. The example
illustrated
by Fig. 14 and the other examples disclosed herein where the strips 24 are
parallel to the
longitudinal direction of the duct assembly 902, the orientation of the duct
liner pieces
may be changed such that the strips 24 are perpendicular to the longitudinal
direction of
the duct assembly.
[0088] Figs. 15 and 16 illustrate an exemplary embodiment that is similar
to the
exemplary embodiment illustrated by Fig. 14, except the duct liner 10 is
secured to the
duct housing 900 by fasteners 908, 1100. In the example illustrated by Figs.
15 and 16,
the fasteners 908, 1100 are secured to the duct housing 900. The fasteners 908
each
extend through one of the strips 26 of the facing 14, through the insulation
layer 12, and
through the central portion 36 of the facing 14 that is disposed on the first
face 20 of the
insulation layer. The fasteners 1100 each extend through the insulation layer
12, and
through the central portion 36 of the facing 14 that is disposed on the first
face 20 of the
insulation layer, but do not extend through one of the strips 26 of the facing
14. This
arrangement securely attaches both the two ends of the duct liner 10 and the
uncovered
portion 30 of the duct liner 10 to the duct housing 900. The strips 26 and/or
the
uncovered portion 30 may also be adhered to the interior surface 904 of the
duct housing
900 by an adhesive.
22
CA 02805785 2013-02-12
[0089] Referring to Fig. 16, the spacing between the fasteners 908, 1100
may be selected
based on the velocity of the air that will flow through the duct. In one
exemplary
embodiment, the spacing between the fasteners 908, 1100 is as follows:
Reference Description Dimension for 0- Dimension for
2500 feet per 2501-6000 feet per
minute minute
A' From corners of duct to 1-2" 1-2"
fasteners 908
From transverse end of duct 1-3" 1-3"
liner
Across width of duct, on 10-14" 4-6"
centers (min. 1 per side)
Along length of duct, on 17-18" 14-16"
centers (min. 1 per side)
[0090] Fig. 17 illustrates another duct assembly configuration. The duct
assembly
illustrated by Fig. 17 is substantially the same as the duct assembly
illustrated by Fig. 14,
except the corners are not compressed. In the example illustrated by Fig. 17,
four pieces
of duct liner 10 are used to insulate the interior surface 904 of the duct
housing 900. The
duct liner 10 is lapped at the corners 1710, 1712, 1714, 1716. Side pieces
1722, 1726
support a top piece 1730. Portion 28 of the facing 14 on the lateral edges 16
engage the
facing 14 on the end of the face surface 22. As such, no portion of the
insulation layer 12
is exposed to the airflow through the duct assembly. The example illustrated
by Fig. 17
and the other examples disclosed herein where the strips 24 are parallel to
the
longitudinal direction of the duct assembly 902, the orientation of the duct
liner pieces
23
CA 02805785 2013-02-12
may be changed such that the strips 24 are perpendicular to the longitudinal
direction of
the duct assembly.
[0091] Figs. 18 and 19 illustrate an exemplary embodiment that is similar
to the
exemplary embodiment illustrated by Fig. 17, except the duct liner 10 is
secured to the
duct housing 900 by fasteners 908, 1100. In the example illustrated by Figs.
18 and 19,
the fasteners 908, 1100 are secured to the duct housing 900. The fasteners 908
each
extend through one of the strips 26 of the facing 14, through the insulation
layer 12, and
through the central portion 36 of the facing 14 that is disposed on the first
face 20 of the
insulation layer. The fasteners 1100 each extend through the insulation layer
12, and
through the central portion 36 of the facing 14 that is disposed on the first
face 20 of the
insulation layer, but do not extend through one of the strips 26 of the facing
14. This
arrangement securely attaches both the two ends of each duct liner 10 and the
uncovered
portion 30 of each duct liner 10 to the duct housing 900. The strips 26 and/or
the
uncovered portion 30 may also be adhered to the interior surface 904 of the
duct housing
900 by an adhesive.
[0092] Referring to Fig. 19, the spacing between the fasteners 908, 1100
may be selected
based on the velocity of the air that will flow through the duct. In one
exemplary
embodiment, the spacing between the fasteners 908, 1100 is as follows:
Reference Description Dimension for 0- Dimension for
2500 feet per 2501-6000 feet per
minute minute
A' From corners of duct to 1-2" 1-2"
fasteners 908
From transverse end of duct 1-3" 1-3"
liner
Across width of duct, on 10-14" 4-6"
24
CA 02805785 2013-02-12
centers (min. 1 per side)
Along length of duct, on 17-18" 14-16"
centers (min. 1 per side)
[0093] Referring to Figs. 20A and 20B, pieces 2000 of duct liner 10 are
secured to L-
shaped sheetmetal panels 2002. The pieces 2000 may be applied to the
sheetmetal panels
2002, before or after the panels are bent into the L-shape. Referring to Fig.
20B, two L-
shaped sheetmetal panels each with two pieces of attached duct liner 10 are
assembled
together to form a duct assembly 902. In other embodiments, the duct housing
900 is
formed from more or less sheetmetal panels. For example, the duct housing 900
may be
formed from a single piece of sheetmetal. The example illustrated by Figs. 20A
and 20B
and the other examples disclosed herein where the strips 24 are parallel to
the
longitudinal direction of the duct assembly 902, the orientation of the duct
liner pieces
may be changed such that the strips 24 are perpendicular to the longitudinal
direction of
the duct assembly.
[0094] Fig. 21 illustrates another duct assembly configuration. In the
example illustrated
by Fig. 21, six pieces of duct liner 10 are used to insulate the interior
surface 904 of the
duct housing 900. The duct liners 10 are lapped at the corners 2110, 2112,
2114, 2116.
Portions 28 of the facing 14 on the lateral edges 16 engage the facing 14 on
the second
surface 22 at the end of the duct liner. Butt joints 2120 are formed between
the top and
bottom duct liners 10. Since the facing 14 extends around the lateral edges
16, the facing
14 of one duct liner 10 engages the facing of the adjacent duct liner at the
butt joints. In
the configuration illustrated by Fig. 21, no portion of the insulation layer
12 is exposed to
the airflow through the duct assembly. The strips 26 and/or the uncovered
portion 30
may be secured to the duct housing 900 in an exemplary embodiment. The example
illustrated by Fig. 21 and the other examples disclosed herein where the
strips 24 are
parallel to the longitudinal direction of the duct assembly 902, the
orientation of the duct
CA 02805785 2013-02-12
liner pieces may be changed such that the strips 24 are perpendicular to the
longitudinal
direction of the duct assembly.
[0095] Fig. 22 illustrates an exemplary embodiment that is similar to the
exemplary
embodiment illustrated by Fig. 21, except the duct liner 10 is secured to the
duct housing
900 by fasteners 908, 1100. In the example illustrated by Fig. 22, the
fasteners 908, 1100
are secured to the duct housing 900. The fasteners 908 each extend through one
of the
strips 26 of the facing 14, through the insulation layer 12, and through the
central portion
36 of the facing 14 that is disposed on the first face 20 of the insulation
layer. The
fasteners 1100 each extend through the insulation layer 12, and through the
central
portion 36 of the facing 14 that is disposed on the first face 20 of the
insulation layer, but
do not extend through one of the strips 26 of the facing 14. This arrangement
securely
attaches both the two ends 918, 920 of the duct liner 10 and the uncovered
portion 30 of
the duct liner 10 to the duct housing 900. The strips 26 and/or the uncovered
portion 30
may also be adhered to the interior surface 904 of the duct housing 900 by an
adhesive.
Figure 22 illustrates an example that shows that a fastener does not have to
extend
through all of the strips 26.
[0096] Fig. 23 illustrates another exemplary embodiment of a duct assembly
902
configuration. In the example illustrated by Fig. 23, a single piece of duct
liner 10 is used
to insulate the entire interior surface 904 of the duct housing 900. The duct
liner 10 is
folded at the corners 2310, 2312, 2314 and 2316. A butt joint 2317 is formed
between
the ends 2318, 2320 of the duct liner 10. The portions 28 of the facing 14 on
the lateral
edges 16 engage one another. No portion of the insulation layer 12 is exposed
to the
airflow through the duct assembly. The strips 26 and/or the uncovered portion
30 may be
secured to the duct housing 900 in an exemplary embodiment.
[0097] Figs. 24A-24D and 25 illustrate an exemplary embodiment where pieces
2500 of
duct liner 10 are secured to L-shaped sheetmetal panels 1302. The pieces 2500
may be
applied to the sheetmetal panels 1302, before or after the panels are bent
into the L-shape.
Referring to 25, two L-shaped sheetmetal panels with attached duct liner 10
are
assembled together to form a duct section 2400. In other embodiments, the duct
housing
26
CA 02805785 2013-02-12
section 2400 is formed from more or less sheetmetal panels. For example, the
duct
housing section 2400 may be formed from a single piece of sheetmetal.
[0098] In the example illustrated by Figs 24A-24D and 25, the leading and
trailing ends
2402, 2404 having edge surfaces 16, 18 that are entirely covered by the facing
14. This
protects the leading and trailing edge surfaces 16, 18 from high velocity
airflow that is
substantially normal to the edge surfaces 16.18. As such, this wrapping of the
edge
surfaces 16, 18 at the leading and trailing edges 2402, 2404 eliminates the
need to install
a metal nosing on the leading edge surface 16 facing the air stream when
velocity
exceeds 4000 FPM. Duct sections 2400 can be assembled in an end to end
relationship to
form an elongated duct assembly. When the sections are assembled, the wrapped
edge
surfaces 16, 18 may be brought into abutment. Since the edge surfaces 16, 18
are
completely covered by the facing 14, no coating is needed on the surfaces 16,
18.
[0099] Referring to Figure 24A, in one exemplary embodiment optional
fasteners 908,
1100 are used to secure to the liner 10 to the duct housing section 2400. The
fasteners
908 each extend through one of the strips 26 of the facing 14, through the
insulation layer
12, and through the central portion 36 of the facing 14 that is disposed on
the first face 20
of the insulation layer. The fasteners 1100 each extend through the insulation
layer 12,
and through the central portion 36 of the facing 14 that is disposed on the
first face 20 of
the insulation layer, but do not extend through one of the strips 26 of the
facing 14. This
arrangement securely attaches both the two ends of the duct liner 10 and the
uncovered
portion 30 of the duct liner 10 to the duct housing 900. The strips 26 and/or
the
uncovered portion 30 may also (or in the alternative) be adhered to the
interior surface
904 of the duct housing 900 by an adhesive.
[00100] The fasteners 1100, 908 can be spaced with respect to the duct housing
900 and
with respect to one another as described in the previous examples. In the
example
exemplary embodiment, the fasteners 908 are spaced from the leading and
trailing ends
2402, 2404 such that the fasteners 908 extend through the strips 24. For
example, the
strips 24 may be 3-4 inches wide and the fasteners may be about 2 inch from
the leading
and trailing edges 2402, 2404. However, any strip width and spacing may be
selected.
27
CA 02805785 2013-02-12
[00101] Figs. 26A-26D illustrate an exemplary embodiment that is similar to
the
embodiment illustrated by Figs. 24A-24D and 25, except two pieces 2500 of duct
liner 10
are secured to each of the L-shaped sheetmetal panels 1302. The pieces 2500
may be
applied to the sheetmetal panels 1302, before or after the panels are bent
into the L-shape.
Referring to 27, two L-shaped sheetmetal panels with attached duct liner 10
are
assembled together to form a length of duct assembly 2400. In other
embodiments, the
duct housing 900 is formed from more or less sheetmetal panels. For example,
the duct
housing 900 may be formed from a single piece of sheetmetal.
[00102] In the example illustrated by Figs 26A-26D and 27, the leading and
trailing ends
2402, 2404 having edge surfaces 16, 18 that are entirely covered by the facing
14. This
protects the leading and trailing edge surfaces 16, 18 from high velocity
airflow that is
substantially normal to the edge surfaces 16.18. Duct sections 2400 can be
assembled in
an end to end relationship to form an elongated duct assembly. When the
sections are
assembled, the wrapped edge surfaces 16, 18 may be brought into abutment.
Since the
edge surfaces 16, 18 are completely covered by the facing 14, no coating is
needed on the
surfaces 16, 18.
[00103] Referring to Figure 26A, in one exemplary embodiment optional
fasteners 908,
1100 are used to secure to the liner 10 duct housing 900. The fasteners 908
each extend
through one of the strips 26 of the facing 14, through the insulation layer
12, and through
the central portion 36 of the facing 14 that is disposed on the first face 20
of the
insulation layer. The fasteners 1100 each extend through the insulation layer
12, and
through the central portion 36 of the facing 14 that is disposed on the first
face 20 of the
insulation layer, but do not extend through one of the strips 26 of the facing
14. This
arrangement securely attaches both the two ends of the duct liner 10 and the
uncovered
portion 30 of the duct liner 10 to the duct housing 900. The strips 26 and/or
the
uncovered portion 30 may also (or in the alternative) be adhered to the
interior surface
904 of the duct housing 900 by an adhesive.
[00104] The fasteners 1100, 908 can be spaced with respect to the duct housing
900 and
with respect to one another as described in the previous examples. In the
example
28
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CA 02805785 2013-02-12
,
exemplary embodiment, the fasteners 908 are spaced from the leading and
trailing ends
2402, 2404 such that the fasteners 908 extend through the strips 24. For
example, the
strips 24 may be 3-4 inches wide and the fasteners may be about 2 inch from
the leading
and trailing edges 2402, 2404. However, any strip width and spacing may be
selected.
[00105] While the present invention has been illustrated by the description of
embodiments thereof, and while the embodiments have been described in
considerable
detail, it is not the intention of the applicant to restrict or in any way
limit the scope of the
appended claims to such detail. Additional advantages and modifications will
readily
appear to those skilled in the art. Still further, while rectangular
components have been
shown and described herein, other geometries can be used including elliptical,
polygonal
(e.g., square, triangular, hexagonal, etc.) and other shapes can also be used.
Therefore,
the invention, in its broader aspects, is not limited to the specific details,
the
representative apparatus, and illustrative examples shown and described.
Accordingly,
departures can be made from such details without departing from the spirit or
scope of
the applicant's general inventive concept.
29
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